Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H45/00—Folding thin material
  • B65H45/02—Folding limp material without application of pressure to define or form crease lines
  • B65H45/06—Folding webs
  • B65H45/10—Folding webs transversely
  • B65H45/101—Folding webs transversely in combination with laying, i.e. forming a zig-zag pile
  • B65H45/1015—Folding webs provided with predefined fold lines; Refolding prefolded webs, e.g. fanfolded continuous forms
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H31/00—Pile receivers
  • B65H31/04—Pile receivers with movable end support arranged to recede as pile accumulates
  • B65H31/08—Pile receivers with movable end support arranged to recede as pile accumulates the articles being piled one above another
  • B65H31/10—Pile receivers with movable end support arranged to recede as pile accumulates the articles being piled one above another and applied at the top of the pile
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H45/00—Folding thin material
  • B65H45/02—Folding limp material without application of pressure to define or form crease lines
  • B65H45/06—Folding webs
  • B65H45/10—Folding webs transversely
  • B65H45/101—Folding webs transversely in combination with laying, i.e. forming a zig-zag pile
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2406/00—Means using fluid
  • B65H2406/30—Suction means
  • B65H2406/34—Suction grippers
  • B65H2406/345—Rotary suction grippers
  • B65H2406/3454—Rotary suction grippers performing oscillating movement during rotation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2406/00—Means using fluid
  • B65H2406/30—Suction means
  • B65H2406/36—Means for producing, distributing or controlling suction
  • B65H2406/365—Means for producing, distributing or controlling suction selectively blowing or sucking
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2701/00—Handled material; Storage means
  • B65H2701/10—Handled articles or webs
  • B65H2701/11—Dimensional aspect of article or web
  • B65H2701/112—Section geometry
  • B65H2701/1123—Folded article or web
  • B65H2701/11231—Fan-folded material or zig-zag or leporello
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2701/00—Handled material; Storage means
  • B65H2701/10—Handled articles or webs
  • B65H2701/17—Nature of material
  • B65H2701/176—Cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
  • B65H2701/00—Handled material; Storage means
  • B65H2701/10—Handled articles or webs
  • B65H2701/17—Nature of material
  • B65H2701/176—Cardboard
  • B65H2701/1762—Corrugated

Definitions

• Exemplary embodiments of the invention relate to the folding and stacking of objects, and more particularly to the folding and stacking of packaging materials. Still more particularly, embodiments relate to stacking of packaging materials, such as packaging and box materials formed of corrugated board.
• the automating of processes has long been a goal of industrialized society, and in virtually any industry in which a product is produced, some type of automated process is likely to be used. Oftentimes, the automated process may make use of modern technological advances that are combined into one or more automated machines that perform functions used to produce a product.
• the product produced by the automated machine may itself make use of raw materials. Such materials may themselves be loaded, provided, or otherwise introduced into the automated machine using an automated process, or such loading may be manual. Particularly where the loading is performed using an automated process, the raw materials may be positioned near the machine to facilitate loading.
• boxes and other types of packaging may be formed out of paper-based products (e.g., corrugated board), and an automated converting machine may be programmed to use one or more available tools to perform a number of different functions on the corrugated board.
• an automated converting machine When loaded into the converting machine, the corrugated board may be cut, scored, perforated, creased, folded, taped, or otherwise manipulated to form a box of virtually any shape and size, or formed into a template that may later be assembled into a box.
• the converting machine starts with a raw form of corrugated board (e.g., fanfold corrugated board in one or more separate feed paths) and converts the raw form into a template form that may then be assembled into a box or other type of package.
• a raw form of corrugated board e.g., fanfold corrugated board in one or more separate feed paths
• the completed product can then be stacked with other similarly configured products to await shipment or use.
• a user may then take one of the packaging templates from the stack and fold it according to the formed scores, perforations, creases, etc.
• the packaging material e.g., fanfold corrugated board
• the packaging material e.g., fanfold corrugated board
• one or more individuals may be positioned at the output end of a machine that produces the desired fanfold.
• those individuals may then fold the fanfold material in a fan-like fashion to form a compact stack.
• such use therefore often necessitates that an individual be stationed at the machine and engage in repetitive movements.
• the production machine may output the product for automated stacking.
• a robotic arm may replace the individual.
• the robotic arm can be programmed to move towards the output end of the machine at the time the product is output.
• the arm can move into engagement with the product.
• the robotic arm can then fold the material in a fan-like fashion.
• Robotic arms can, therefore, also effectively stack materials.
• Such arms may, however, be complex to manufacture and/or program, such that it would be desirable for a simplified system for reliably and effectively stacking materials.
• Another challenge with such mechanical arms is being able to move them away from the folded material quickly enough to allow the material to fold onto itself without the mechanical arm being caught between folded layers.
• Exemplary embodiments of the disclosure relate to the folding and stacking of linearized fanfold corrugated board material and similar continuous or semi- continuous packaging materials. More particularly, linearized fanfold material may be folded and stacked by a system that includes a rotatable member (e.g., a wheel) having a number of head pieces disposed on the rotatable member. Each head piece has a vacuum setting that can be used to pick up a portion of a length of fanfold and hold it while the rotatable member rotates around its axis and an optional second blower setting that blows the portion of the length of fanfold that was picked up and rotated around the rotatable member down onto a stack of fanfold.
• a rotatable member e.g., a wheel
• head piece has a vacuum setting that can be used to pick up a portion of a length of fanfold and hold it while the rotatable member rotates around its axis and an optional second blower setting that blows the portion of the length of fanfold that was picked up
• Such a system is capable of forming regular and consistent stacks of fanfold material efficiently and cost effectively without the need for significant human intervention.
• the folding and stacking systems and methods described herein are able to efficiently fold and stack fanfold material using mechanisms that are much less complex and less costly as compared to industrial robots and the like.
• a system for folding and stacking fanfold material includes a rotatable member having at least two head pieces disposed on the rotatable member circumferentially offset from one another.
• the rotatable member is rotatable about an axis (e.g., a central axis).
• Each head piece positioned on the rotatable member has a first vacuum setting configured to engage a portion of a length of scored or creased fanfold material so as to rotate it around the axis and a second blower setting configured to blow the portion of the length of scored or creased fanfold material away from the rotatable member at a predetermined position around the axis so as to form a stack of folded fanfold material.
• another system for folding and stacking fanfold material includes a conveyor having a first end and a second end.
• the conveyor may be configured to convey a first end of a length of a fanfold material from the first end of the conveyor to the second end of the conveyor.
• a rotatable member may be positioned adjacent to the second end of the conveyor.
• the rotatable member may be rotatable about an axis such that the rotatable member can receive the fanfold material from the second end of the conveyor and rotate the fanfold material at least partially about the axis of the rotatable member.
• the rotatable member may have at least two head pieces disposed thereon and which are circumferentially offset from one another.
• the system may also include a hopper positioned adjacent to the rotatable member and opposite the second end of the conveyor such that the hopper can receive folded fanfold material delivered by the rotatable member.
• the hopper can be configured to be removably attached to a shipping pallet or a similar article designed for storing and shipping a stack of fanfold.
• the hopper may include a mechanism, such as an elevator component, that maintains the top of the stack of folded fanfold material at a generally constant height or vertical position as additional layers of fanfold material are added to the stack.
• the elevator mechanism may lower the stack of fanfold material as additional layers of material are added to the stack in order to maintain the top of the stack at a relatively constant height or vertical position.
• maintaining a relatively constant height or vertical position of the top of the stack can reduce or eliminate the need for the head piece(s) to adjust the location(s) where the fanfold material is released therefrom.
• each head piece positioned on the rotatable member can have a first vacuum setting configured to engage a portion of a length of scored or creased fanfold material so as to rotate it around the axis and a second blower setting configured to blow the portion of the length of scored or creased fanfold material away from the rotatable member at a predetermined position around the axis so as to form a stack of folded fanfold material.
• a method for folding and stacking fanfold material includes (i) delivering a first end of a length of a fanfold material to a rotatable member having at least two head pieces disposed on the rotatable member and which are circumferentially offset from one another, (ii) rotating the rotatable member about a central axis while simultaneously continuing to deliver the fanfold material to the rotatable member, (iii) engaging a portion of the length of scored or creased fanfold material by vacuum with a first head piece so as to rotate the portion of the length of scored or creased fanfold material around the central axis, and (iv) switching the first head piece to a blower setting at a predetermined position around the axis so as to blow the portion of the length of scored or creased fanfold material away from the rotatable member so as to form a stack of folded fanfold material.
• the method further includes (v) stacking the stack of folded fanfold material
• Figure 1 illustrates a perspective view of a vacuum wheel fanfold stacker, according to an exemplary embodiment of the present disclosure
• Figures lA-10 illustrate the vacuum wheel fanfold stacker of Figure 1 in various operational positions while stacking fanfold material
• Figure 2 illustrates a perspective view of a rotatable member having a pneumatic control system, according to an exemplary embodiment of the present disclosure
• Figure 3 illustrates a perspective view of an expandable rotatable member that can accommodate fanfold material having different inter-score distances, according to an exemplary embodiment of the present disclosure.
• Exemplary embodiments of the disclosure relate to the folding and stacking of linearized fanfold corrugated board material and similar continuous or semi-continuous packaging materials. More particularly, linearized fanfold material may be folded and stacked by a system that includes a rotatable member (e.g., a wheel) having a number of head pieces disposed on the rotatable member. Each head piece has a vacuum setting that can be used to pick up a portion of a length of fanfold and hold it while the rotatable member rotates around its axis and an optional second blower setting that blows the portion of the length of fanfold that was picked up and rotated around the rotatable member down onto a stack of fanfold.
• a rotatable member e.g., a wheel
• head piece has a vacuum setting that can be used to pick up a portion of a length of fanfold and hold it while the rotatable member rotates around its axis and an optional second blower setting that blows the portion of the length of fanfold that was picked
• the blower setting is activated after the vacuum setting is deactivated.
• a system is capable of forming regular and consistent stacks of fanfold material efficiently and cost effectively without the need for significant human intervention.
• the folding and stacking systems and methods described herein are able to efficiently fold and stack fanfold material using mechanisms that are much less complex and less costly as compared to industrial robots and the like.
• fanfold is used to refer to any type of packaging or other type of material that is manufactured in long sheets that are folded into relatively compact stacks in a fan-like or accordion-like fashion.
• fanfold is a corrugated cardboard material; however, other packing materials such as paperboard can be manufactured as fanfold material.
• Typical corrugated fanfold packaging material is produced in single and double wall corrugated fashions, which are available in most liner grades.
• Typical widths of commercially available fanfold range from about 12 inches (about 30 cm) to about 98 inches (about 250 cm or 2.5 meters).
• Typical fold lengths range from about 20 inches (about 50 cm) to about 90 inches (about 230 cm), and are commonly about 40 inches (about 100 cm).
• fanfold may also include a variety of intermediate scoring designs, coatings, printing, and the like.
• a single, continuous sheet of fanfold can exceed about 2300 linear feet (about 700 meters) in length. Fanfold is typically folded to fit on top of a pallet or slip sheet.
• packing materials is utilized herein to generically describe a variety of different types of materials that may be converted using a converting machine.
• "packaging materials” may be used to effectively refer to any material that can be converted from a raw form into a usable product, or into a template for a usable product.
• paper-based materials such as cardboard, corrugated board, paper board, and the like may be considered “packaging materials” although the term is not necessarily so limited. Accordingly, while examples herein describe the use of corrugated board and fanfold corrugated board, such are merely exemplary and not necessarily limiting of the present application.
• Figures 1-3 and the following discussion are intended to provide a brief general description of exemplary devices in which embodiments of the disclosure may be implemented. While a vacuum wheel fanfold stacker system for folding and stacking fanfold materials is described below, this is but one single example, and embodiments of the disclosure may be implemented with other types of materials. Accordingly, throughout the specification and claims, the phrases “fanfold material,” “fanfold stack,” and “fanfold” and the like are intended to apply broadly to any type of item that can be folded and stacked by the vacuum wheel fanfold stacker system described herein. [0027] Figures 1-3 thus illustrate one example of a vacuum wheel fanfold stacker system implementing some aspects of the present disclosure.
• the exemplary vacuum wheel fanfold stacker system is broadly illustrated to include a rotatable member 20 having a plurality of head pieces 30a-30d circumferentially attached thereto.
• the vacuum wheel fanfold stacker system further includes a conveyor 80, a hopper 90, and, optionally, an electronic control system shown schematically at 100.
• the conveyor 80 includes a first end 82 and a second end 84.
• the rotatable member 20 includes a box- shaped frame 22 that has a generally square profile.
• the box-shaped frame 22 is disposed on a round wheel 24.
• box-shaped frame 22 may be configured such that the rotatable member 20 can support fanfold material 50 as it engages with the rotatable member 20.
• the box-shaped frame of the rotatable member may have other profiles such as, but not limited to, round, triangular, hexagonal, star-shaped, and the like.
• the rotatable member 20 includes four head pieces 30a-30d.
• the rotatable member 20 may, for example, include one, two, three, or more than four head pieces.
• the head pieces 30a-30d are positioned at the corners of the box-shaped frame 22 of the rotatable member 20.
• the rotatable member 20 may, for example, include head pieces at one or more intermediate positions between the corners of the box-shaped frame 22 of the rotatable member 20, such midway between of the corners of the box-shaped frame 22.
• linear fanfold material 50 is conveyed by the conveyor 80 from the first end 82 to the second end 84 where it is picked up by the rotatable member 20.
• the linear fanfold material 50 is then rotated around the rotatable member 20 and folded into the hopper 90 to form a fanfold stack 70.
• the fanfold material 50 is corrugated board material having a number of crease lines or score marks 60 separated by distance d.
• the plurality of head pieces 30a-30d on the rotatable member 20 are spaced apart by distance d', which is substantially equal to distance d in the illustrated embodiment, such that the rotatable member 20 can engage with a portion of linear fanfold material 50 of length d between creases 60 without creating additional creases in the fanfold material 50 as the rotatable member 20 rotates about its axis 40.
• the distance d' is a multiple of distance d, such that the rotatable member 20 can engage and only fold the fanfold material 50 at non-sequential creases 60.
• the rotatable member 20 rotates about its axis 40, some of the head pieces 30a-30d will become positioned such that they can pneumatically engage with the fanfold material 50 by vacuum.
• head pieces 30b and 30c are pneumatically engaged with the fanfold material 50.
• the pneumatically engaged head pieces hold onto the fanfold and rotate it about axis 40.
• the engaged head pieces e.g., 30b and 30c
• the engaged head pieces can turn off the vacuum setting, thereby disengaging the head pieces from the fanfold material 50 and allowing the fanfold material 50 to descend onto the fanfold stack 70.
• a blower setting may be activated to cause the head pieces to blow the linear fanfold material 50 down onto the fanfold stack 70. Blowing the fanfold material 50 down onto the stack 70 as opposed to allowing it to fall by gravity alone may increase the rate at which fanfold material 50 can be stacked. As the rotatable member 20 rotates about its axis 40, each of the head pieces 30a-30d may become engaged with and subsequently disengaged from a portion of the length of fanfold material 50.
• a control system can be used to activate/deactivate the vacuum and/or blower settings of the head pieces 30a-30d.
• vacuum settings can be activated/deactivated on one or more of the head pieces 30a-30d when the one or more head pieces 30a-30d are positioned between certain locations about axis 40.
• blower settings may be activated/deactivated on one or more of the head pieces 30a-30d when the one or more head pieces 30a-30d are positioned between certain locations about axis 40.
• a vacuum setting on the head piece 30a may be activated when the head piece 30a is in the positions shown in Figures 1 A-1F or when the head piece 30a moves through an arc between the positions shown in Figures 1A and IF.
• a vacuum setting on the head piece 30b may be activated when the head piece 30b is in the positions shown in Figures 1A-1B and lL-10 or when the head piece 30b moves through an arc between the positions shown in Figures 1L and IB.
• a vacuum setting on the head piece 30c may be activated when the head piece 30c is in the positions shown in Figures 1H-1M or when the head piece 30C moves through an arc between the positions shown in Figures 1H and 1M.
• a vacuum setting on the head piece 30d may be activated when the head piece 30d is in the positions shown in Figures 1E-1I or when the head piece 30d moves through an arc between the positions shown in Figures IE and II.
• a blower setting on the head piece 30a may be activated when the head piece 30a is in the positions shown in Figures 1G-1H or when the head piece 30a moves through an arc between the positions shown in Figures 1G and 1H.
• a blower setting on the head piece 30b may be activated when the head piece 30b is in the positions shown in Figures 1C-1D or when the head piece 30b moves through an arc between the positions shown in Figures 1C and ID.
• a blower setting on the head piece 30c may be activated when the head piece 30c is in the positions shown in Figures lN-1 A or when the head piece 30c moves through an arc between the positions shown in Figures IN and 1A.
• a blower setting on the head piece 30d may be activated when the head piece 30d is in the positions shown in Figures 1J-1K or when the head piece 30d moves through an arc between the positions shown in Figures 1 J and IK.
• control systems may deactivate both the vacuum and blower settings, providing the head pieces with an "off setting".
• the off settings on the head pieces 30a-30d made be used during a portion of the rotation of the head pieces 30a-30d about axis 40.
• the vacuum and blower settings for head piece 30a may be deactivated when the head piece 30a is in the positions shown in Figures 1I-1N or when the head piece 30a moves through an arc between the positions shown in Figures II and IN.
• the vacuum and blower settings for head piece 30b may be deactivated when the head piece 30b is in the positions shown in Figures 1E-1K or when the head piece 30b moves through an arc between the positions shown in Figures IE and IK.
• the vacuum and blower settings for head piece 30c may be deactivated when the head piece 30c is in the positions shown in Figures 1B-1G or when the head piece 30c moves through an arc between the positions shown in Figures IB and 1G.
• the vacuum and blower settings for head piece 30d may be deactivated when the head piece 30d is in the positions shown in Figures 1A-1D and lL-10 or when the head piece 30d moves through an arc between the positions shown in Figures 1L and ID.
• each of the head pieces 30a- 30d can be controlled and changed as the head pieces 30a-30d rotate about axis 40. More specifically, each of the head pieces 30a-30d can cycle through the vacuum, blower, and off settings as the head pieces 30a-30d rotate about axis 40.
• the head piece 30a may have: (i) a vacuum setting activated through a first portion of the travel path about axis 40; (ii) a blower setting activated through a second portion of the travel path about axis 40; and (ii) an off setting activated through a third portion of the travel path about axis 40.
• the lengths of the first, second and third portions of the travel path may be different for different head pieces.
• the first portion of the travel path for the head pieces 30a, 30c may be longer than the first portion of the travel path for the head pieces 30b, 30d.
• the vacuum settings for the head pieces 30a, 30c may be activated for a longer time than the vacuum settings for the head pieces 30b, 30d.
• the travel lengths and/or activation times for the blower and off settings for the heads 30a, 30c may also differ from the travel lengths and/or activation times for the blower and off settings for the heads 30b, 30d. It will also be understood that the travel lengths and/or activation times for each of the settings for each of the head pieces 30a-30d may differ from one another or may be the same as one another.
• the stack of fanfold material 70 may be formed of a plurality of different layers of fanfold material 50.
• a score line 60 may be formed at the opposing edges of each layer of fanfold 50 in the stack of fanfold material 70; score lines 60 can demark the transition from one layer to the next.
• Each layer may be generally positioned in the stack 70 such that it is vertically higher than a prior layer, and vertically lower relative to a subsequent layer. It will be appreciated that the stack 70 may be arranged in different orientations, such as horizontal or angled. For instance, in a horizontally oriented stack, each layer may be generally positioned horizontally to one side of another layer.
• each layer may be generally positioned both horizontally and vertically relative to an adjacent layer.
• a particular aspect of the score lines 60 formed in fanfold material 50 is that they allow fanfold material 50 to fold over itself to form the multiple layers of the fanfold stack 70.
• score lines can be at the edges of the fanfold stack.
• the fanfold stack 70 is formed in hopper 90.
• the hopper 90 includes a plurality of vertical members 92 that are separated from one another. Separating the plurality of vertical members 92 may, for example, permit the fanfold material 50 to stack more efficiently because air that may otherwise become trapped between layers can readily escape between the vertical members 92.
• Each of the plurality of vertical members 92 may also include a curved upper portion 94 such that the rotatable member 20 is able to rotate substantially within the confines of the hopper without getting bound up on the vertical members 92.
• the curved upper portions 94 may also assist with directing the fanfold material 50 into the hopper 90.
• the electronic control system 100 may be linked to one or both of conveyor 80 or the rotatable member 20 via communication lines 102 and 104, respectively.
• the electronic control system 100 may, for example, set and/or adjust the speed of one or both of the conveyor 80 or the rotatable member 20 such that fanfold material 50 is fed to the rotatable member 20 at a rate that allows the fanfold material 50 to be cleanly and efficiently stacked.
• the electronic control system 100 may be linked to a number of other control/feedback devices (not shown) such as speed sensors, electronic eyes or cameras, and the like that allow fanfold material 50 to be fed to the rotatable member 20 such that the creases 60 are correctly positioned relative to the head pieces 30a-30d and that the fanfold material 50 is cleanly and efficiently stacked.
• other control/feedback devices such as speed sensors, electronic eyes or cameras, and the like that allow fanfold material 50 to be fed to the rotatable member 20 such that the creases 60 are correctly positioned relative to the head pieces 30a-30d and that the fanfold material 50 is cleanly and efficiently stacked.
• the pneumatic control system 200 may be an electronic control system that controls the timing and application of vacuum and/or compressed air or it may be linked to the electronic control system 100.
• the pneumatic control system 200 may also include a vacuum source and/or a compressed air source (shown collectively at 205) that is linked to each of the head pieces 30a-30d. Accordingly, the pneumatic control system 200 and/or the electronic control system 100 may control the activation of the vacuum, blower, and/or off settings (as described elsewhere herein) for the head pieces 30a- 30d.
• the vacuum source/compressed air source 205 is connected to a manifold 230 that distributes vacuum lines 210 and compressed air lines 220 to each of the head pieces 30a-30d.
• the manifold 230 may be a stationary connection that maintains pneumatic connection between the vacuum source/compressed air source 205 and each of the head pieces 30a-30d as the rotatable member 20 rotates about axis 40.
• Such devices are known to those having skill in the pneumatic arts.
• similar manifolds or one type of manifold that can be employed is the so-called "on the fly" tire inflation/deflation systems that are equipped on some automobiles.
• FIG. 3 perspective views of an expandable rotatable member 300 are shown in first and second configurations.
• the expandable nature of the rotatable member 300 enables the rotatable member 300 to accommodate fanfold materials having different inter-score distances.
• the rotatable member 300 can be selectively adjusted, resized, or reconfigured so that the distance between adjacent head pieces 30a-30d generally corresponds to the inter-score distance of a desired fanfold material.
• Figure 3 illustrates the rotatable member 300 in a first configuration in which there is a distance d'i between adjacent head pieces 30a-30d.
• the distance d'i between adjacent head pieces 30a-30d generally corresponds to the inter-score distances di of the fanfold material 350.
• the head pieces 30a- 30d engage the fanfold material 350 near the fanfold creases to stack the fanfold material 350 into a stack, as discussed above.
• the rotatable member 300 can be selectively adjusted, resized, or reconfigured to accommodate the different inter-score distance of the different fanfold material. For instance, as shown in Figure 3, the rotatable member 300 may be selectively adjusted, resized, or reconfigured so that a new distance d' 2 between adjacent head pieces 30a-30d generally corresponds to the inter- score distances d 2 of the fanfold material 355.
• the rotatable member 300 may be selectively adjusted, resized, or reconfigured in a variety of ways.
• the frame 22' of the rotatable member 300 may be formed of expandable/contractable components.
• each side of the frame 22' may be formed of telescoping rods or tubes that allow for the length of each side of the frame 22' to be selectively increased or decreased so as to move the head pieces 30a-30d further apart or closer together.
• the head pieces 30a-30d and/or parts of the frame 22' may be pivotally mounted such that the head pieces 30a-30d and/or parts of the frame 22' may be pivoted closer to or further from the rotational axis 40 of the rotatable member 300.
• the rotatable member 300 may be selectively adjusted, resized, or reconfigured in a reversible manner. That is, the size of the rotatable member 300 may be selectively increased and later selectively decreased, and vice versa. Furthermore, while Figure 3 only illustrates the rotatable member 300 in two size configurations, this is merely for convenience.
• An expandable rotatable member may be configured to be expandable/contractable to substantially any size to accommodate substantially any size of fanfold material.
• a fanfold stacker system may be equipped with multiple rotatable members having a variety of sizes to accommodate different sizes of fanfold material.
• Figures lA-10 illustrate a number of views of a method for stacking fanfold material using a system for folding and stacking fanfold material as illustrated in Figure 1.
• a method for folding and stacking fanfold material may include (i) delivering a first end of a length of a fanfold material to a rotatable member having at least two head pieces disposed on the rotatable member and which are circumferentially offset from one another, (ii) rotating the rotatable member about a central axis while simultaneously continuing to deliver the fanfold material to the rotatable member, (iii) engaging a portion of the length of scored or creased fanfold material by vacuum with a first head piece so as to rotate the portion of the length of scored or creased fanfold material around the central axis, and (iv) deactivating the vacuum and/or switching the first head piece to a blower setting at a predetermined position around the axis so as to blow the portion of the length of scored or creased fanfold material away from the rotatable member so as to form a stack of folded fanfold material.
• the method further includes (v) stacking the stack of folded fanfold material in a hopper positioned adjacent to the rotatable member.
• the blower setting may be able push the fanfold material down onto the stack more quickly than simply allowing the fanfold to descend by gravity alone, thereby increasing the rate at which fanfold can be stacked.
• the fanfold material includes a number of substantially evenly spaced score lines or crease lines positioned on the fanfold material substantially perpendicular to a long edge of the fanfold material.
• the fanfold material is formed without the score or crease lines.
• the fanfold stacker may create creases or folds in the fanfold material as the fanfold stacker rotates the fanfold material thereabout, as described herein. More specifically, the rotation of the fanfold material may force-fold the material, thereby creating regularly spaced creases that allow the material to be stacked as described herein.
• the method further includes detecting a position of one or more of the score lines or crease lines in the length of the fanfold material, and updating the relative timing of one or more of steps (i)-(iv) as a function of the position of the score lines or crease lines in the length of the fanfold material.
• a first head piece engages the fanfold material adjacent to a first score line or crease line and a second head piece engages the fan fold material adjacent to a second score line or crease line.
• the method further includes delivering the first end of the length of a fanfold material using a conveyor positioned adjacent to the rotatable member.
• the stack of folded fanfold material is stacked in a zigzag pattern such that, when viewed from the side of the stack, there are left folds and right folds.
• switching the first head piece to the blower setting occurs at a first predetermined position if forming a left fold and at a second predetermined position if forming a right fold.
• Figure 1C and 1G Compare, for example, Figures 1C and 1G.
• Figure 1C shows a left fold being formed (adjacent the head piece 30b). In such a case, the head piece releases the fanfold material when the fanfold material is hanging about vertically (or is oriented about perpendicular to the end of the stack).
• Figure 1G shows a right fold being formed (adjacent the head piece 30a).
• the head piece engages with the fanfold material relatively longer and releases the fanfold material when the fanfold material is rotated about the rotatable member until the fanfold is hanging well past vertical (or is oriented at an acute angle relative to the end of the stack).
• Such a system may, for example, allow the fanfold stacker system to direct the fanfold so that it is efficiently and regularly folded.

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• 2016
  • 2016-10-27 JP JP2018522134A patent/JP6799595B2/ja active Active
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  • 2016-10-27 US US15/770,864 patent/US10954096B2/en active Active
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